Method for preparing substituted 4-phenyl-4-cyanocylohexanoic acids

ABSTRACT

This invention relates to a method of preparing a compound type where at least one of R′ or R″ is a carbosyl group (I) by treating a compound of formula (II) with a Group I(a) or Group II(a) metal halide, with an aprotic dipolar amide-based solvent and water.

SCOPE OF THE INVENTION

[0001] This invention covers intermediates and a synthetic route formaking 4-cyano-4-(3-cyclopentyloxy-4-methoxyphenyl)cyclohexanoic acidand its analogs. This acid and its named analogs are selective forinhibiting the catalytic site in the phosphodiesterase isoenzymedenominated IV (PDE IV hereafter) and as such the acids are useful intreating a number of diseases which can be moderated by affecting thePDE IV enzyme and its subtypes.

AREA OF THE INVENTION

[0002] Bronchial asthma is a complex, multifactorial diseasecharacterized by reversible narrowing of the airway and hyper-reactivityof the respiratory tract to external stimuli.

[0003] Identification of novel therapeutic agents for asthma is madedifficult by the fact that multiple mediators are responsible for thedevelopment of the disease. Thus, it seems unlikely that eliminating theeffects of a single mediator will have a substantial effect on all majorcomponents of chronic asthma. An alternative to the “mediator approach”is to regulate the activity of the cells responsible for thepathophysiology of the disease.

[0004] One such way is by elevating levels of cAMP (adenosine cyclic3′,5′-monophosphate). Cyclic AMP has been shown to be a second messengermediating the biologic responses to a wide range of hormones,neurotransmitters and drugs; [Krebs Endocrinology Proceedings of the 4thInternational Congress Excerpta Medica, 17-29, 1973]. When theappropriate agonist binds to specific cell surface receptors, adenylatecyclase is activated, which converts Mg⁺²-ATP to cAMP at an acceleratedrate.

[0005] Cyclic AMP modulates the activity of most, if not all, of thecells that contribute to the pathophysiology of extrinsic (allergic)asthma. As such, an elevation of cAMP would produce beneficial effectsincluding: 1) airway smooth muscle relaxation, 2) inhibition of mastcell mediator release, 3) suppression of neutrophil degranulation, 4)inhibition of basophil degranulation, and 5) inhibition of monocyte andmacrophage activation. Hence, compounds that activate adenylate cyclaseor inhibit phosphodiesterase should be effective in suppressing theinappropriate activation of airway smooth muscle and a wide variety ofinflammatory cells. The principal cellular mechanism for theinactivation of cAMP is hydrolysis of the 3′-phosphodiester bond by oneor more of a family of isozymes referred to as cyclic nucleotidephosphodiesterases (PDEs).

[0006] It has now been shown that a distinct cyclic nucleotidephosphodiesterase (PDE). isozyme, PDE IV, is responsible for cAMPbreakdown in airway smooth muscle and inflammatory cells. [Torphy,“Phosphodiesterase Isozymes: Potential Targets for Novel Anti-asthmaticAgents” in New Drugs for Asthma, Barnes, ed. IBC Technical ServicesLtd., 1989]. Research indicates that inhibition of this enzyme not onlyproduces airway smooth muscle relaxation, but also suppressesdegranulation of mast cells, basophils and neutrophils along withinhibiting the activation of monocytes and neutrophils. Moreover, thebeneficial effects of PDE IV inhibitors are markedly potentiated whenadenylate cyclase activity of target cells is elevated by appropriatehormones or autocoids, as would be the case in vivo. Thus PDE IVinhibitors would be effective in the asthmatic lung, where levels ofprostaglandin E₂ and prostacyclin (activators of adenylate cyclase) areelevated. Such compounds would offer a unique approach toward thepharmacotherapy of bronchial asthma and possess significant therapeuticadvantages over agents currently on the market.

[0007] The process and intermediates of this invention provide a meansfor making certain4-substituted-4-(3,4-disubstitutedphenyl)cyclohexanoic acids which areuseful for treating asthma, and other diseases which can be moderated byaffecting the PDE IV enzyme and its subtypes. The final products ofparticular interest are fully described in U.S. Pat. No. 5,552,483issues Sep. 3, 1996. The information and representations disclosedtherein, in so far as that information and those representations arenecessary to the understanding of this invention and its practice, intotal, are incorporated herein by reference.

SUMMARY OF THE INVENTION

[0008] This invention relates a method for making a compound of formulaI

[0009] wherein

[0010] R₁ is —(CR₄R₅)_(n)C(O)O(CR₄R₅)_(m)R₆,—(CR₄R₅)_(n)C(O)NR₄(CR₄R₅)_(m)R₆, —(CR₄R₅)_(n)O(CR₄R₅)_(m)R₆, or—(CR₄R₅)_(r)R₆ wherein the alkyl moieties may be optionally substitutedwith one or more halogens;

[0011] m is 0 to 2;

[0012] n is 1 to 4;

[0013] r is 0 to 6;

[0014] R₄ and R₅ are independently selected from hydrogen or a C₁₋₂alkyl;

[0015] R₆ is hydrogen, methyl, hydroxyl, aryl, halo substituted aryl,aryloxyC₁₋₃ alkyl, -halo substituted aryloxyC₁₋₃ alkyl, indanyl,indenyl, C₇₋₁₁ polycycloalkyl, tetrahydrofuranyl, furanyl,tetrahydropyranyl, pyranyl, tetrahydrothienyl, thienyl,tetrahydrothiopyranyl, thiopyranyl, C₃₋₆ cycloalkyl, or a C₄₋₆cycloalkyl containing one or two unsaturated bonds, wherein thecycloalkyl and heterocyclic moieties may be optionally substituted by 1to 3 methyl groups or one ethyl group;

[0016] provided that:

[0017] a) when R₆ is hydroxyl, then m is 2; or

[0018] b) when R₆ is hydroxyl, then r is 2 to 6; or

[0019] c) when R₆ is 2-tetrahydropyranyl, 2-tetrahydrothiopyranyl,2-tetrahydrofuranyl, or 2-tetrahydrothienyl, then m is 1 or 2; or

[0020] d) when R₆ is 2-tetrahydropyranyl, 2-tetrahydrothiopyranyl,2-tetrahydrofuranyl, or 2-tetrahydrothienyl, then r is 1 to 6;

[0021] e) when n is 1 and m is 0, then R₆ is other than H in—(CR₄R₅)_(n)O(CR₄R₅)_(m)R₆;

[0022] X is YR₂, halogen, nitro, NH₂, or formyl amine;

[0023] X₂ is 0 or NR₈;

[0024] Y is 0 or S(O)m,

[0025] m′ is 0, 1, or 2;

[0026] R₂ is independently selected from —CH₃ or —CH₂CH₃ optionallysubstituted by 1 or more halogens;

[0027] R₃ is hydrogen, halogen, C₁₋₄ alkyl, CH₂NHC(O)C(O)NH₂,halo-substituted C₁₋₄ alkyl, —CH═CR_(8′)R_(8′), cyclopropyl optionallysubstituted by R_(8′), CN, OR₈, CH₂OR₈, NR₈R₁O, CH₂NR₈R₁₀, C(Z)H,C(O)OR₈, C(O)NR₈R₁O, or C≡CR_(8′);

[0028] R₈ is hydrogen or C₁₋₄ alkyl optionally substituted by one tothree fluorines;

[0029] R_(8′) is R₈ or fluorine;

[0030] R₁₀ is OR₈ or R₁₁;

[0031] R₁₁ is hydrogen, or C₁₋₄ alkyl optionally substituted by one tothree fluorines;

[0032] Z′ is O, NR₉, NOR₈, NCN, C(—CN)₂, CR₈CN, CR₈NO₂, CR₈C(O)OR₈,CR₈C(O)NR₈R₈, C(—CN)NO₂, C(—CN)C(O)OR₉, or C(—CN)C(O)NR₈R₈;

[0033] R′ and R″ are independently hydrogen or —C(O)OX where X ishydrogen or metal or ammonium cation;

[0034] which method comprises:

[0035] a) combining a Group I(a) or Group II(a) metal halide, with anaprotic dipolar amide-based solvent and water and a compound of formulaA or B,

[0036]  where R₁, R₃, X₂ and X are the same as for formula (I);

[0037] b) heating the combination to a temperature of at least about 60°for several hours, optionally under an inert atmosphere;

[0038] c) precipitating out a compound of formula (I) by adding a strongbase to said combination;

[0039] d) removing the amide-based solvent and water from saidprecipitate, and optionally

[0040] 1) purifying further the precipitate, or

[0041] 2) acidifying the precipitate to obtain the free acid.

SPECIFIC EMBODIMENTS OF THE INVENTION

[0042] This process involves the synthesis of certain4-substituted-4-(3,4-disubstitutedphenyl)cyclohexanoic acids. It allowsfor converting a cyanoepoxide to its corresponding homologated acid viathe use of a Group I(a) or II(b) salt intermediate.

[0043] The compounds which are made by this process are PDE IVinhibitors. They are useful for treating a number of diseases asdescribed in U.S. Pat. No. 5,552,438 issued Sep. 3, 1996.

[0044] The preferred compounds which can be made by this process are asfollows:

[0045] Preferred R₁ substitutents for the compounds of all namedformulas are CH₂-cyclopropyl, CH₂-C₅₋₆ cycloalkyl, C₄₋₆ cycloalkylunsubstituted or substituted with OHC₇₋₁₁ polycycloalkyl, (3- or4-cyclopentenyl), phenyl, tetrahydrofuran-3-yl, benzyl or C₁₋₂ alkylunsubstituted or substituted by 1 or more fluorines,—(CH₂)₁₋₃C(O)O(CH₂)₀₋₂CH₃, —(CH₂)₁₋₃O(CH₂)₀₋₂CH₃, and —(CH₂)₂₋₄OH.

[0046] Preferred X groups for Formula (I) or (II) are those wherein X isYR₂ and Y is oxygen. The preferred X₂ group for Formula (I) is thatwherein X₂ is oxygen. Preferred R₂ groups are a C₁₋₂ alkyl unsubstitutedor substituted by 1 or more halogens. The halogen atoms are preferablyfluorine and chlorine, more preferably fluorine. More preferred R₂groups are those wherein R₂ is methyl, or the fluoro-substituted alkyls,specifically a C₁₋₂ alkyl, such as a —CF₃, —CHF₂, or —CH₂CHF₂ moiety.Most preferred are the —CHF₂ and —CH₃ moieties.

[0047] Most preferred are those compounds wherein R₁ is—CH₂-cyclopropyl, cyclopentyl, 3-hydroxycyclopentyl, methyl or CF₂H; Xis YR₂; Y is oxygen; X₂ is oxygen; and R₂ is CF₂H or methyl; and R₃ isCN.

[0048] The lithium salt of these compound represent a sub-set ofpreferred compounds. In particular the lithium salt of4-cyano-4-(3-cyclopentyloxy-4-methoxyphenyl)-r-1-cyclohexanecarboxylicacid, i.e.,lithium-4-cyano-4-(3-cyclopentyloxy-4-methoxyphenyl)-r-1-cyclohexanecarboxylaterepresents a preferred embodiment. More particularly, the compoundcis-lithium-4-cyano-4-(3-cyclopentyloxy-4-methoxyphenyl)-r-1-cyclohexanecarboxylateis most preferred.

[0049] The carboxylate is made by opening the epoxide with a Group I(a)or II(a) metal halide to get the acyl nitrile which hydrolyzes to theacid in the presence of water. A problem in preparing the acid from theacyl nitrile is that when the carboxylate is formed from the acylnitrile, hydrogen cyanide (HCN) is generated. The challenge is one ofremoving this HCN in a cost-effective way. A feature of this inventionis a means for effecting a more efficient removal of HCN. It has beendiscovered that if the reaction is run in an aprotic dipolar amide-basedsolvent containing water, when a strong base is added a cyanide saltforms and remains in solution and the carboxylate salt which forms atthe same time precipitates out of solution. This permits one to collectthe precipitate and remove the solvent, and by that means remove most oressentially all of the cyanide salt from the alkanoic acid saltprecipitate. This avoids having to run an extra purification step, suchas oxidizing the HCN.

[0050] The Group I(a) or II(a) metal halides used in this invention areany of the halides of the alkali metals and the alkali earth metals,i.e., lithium, sodium, potassium, rubidium, cesium or francium; andberyllium, magnesium, calcium, strontium, barium, or radium. Thepreferred metals are lithium and magnesium. The halides includefluoride, chloride, bromide and iodide. The preferred halide is bromide.Lithium and magnesium halides are preferred. Lithium bromide andmagnesium bromide are most preferred. Lithium bromide is particularlypreferred.

[0051] In regards to the amide-based solvents, they are illustrated bythe likes of dimethylformamide (DMF), dimethylacetamide, and N-methylpyrrolidinone. DMF is most preferred. A second organic solvent can beused in addition to the amide-based solvent. For example acetonitrilehas been used successfully in the reaction illustrated below. Normallywater is added to the reaction pot as it hydrolyzes the acyl nitrile insitu to give the alkanoic acid. Hence a further preferred embodiment ofthis invention is to use an aprotic dipolar solvent which is watermiscible. DMF, dimethylacetamide, and N-methyl pyrrolidinone meet thisstandard. While it is essential to have water in the reaction medium,the amount of water can vary widely. The reaction goes even when a minoramount of water is present. It is preferred to have at least 0.1% byweight/weight (wt/wt) present in the reaction vessel, calculated on thebasis of both the liquids and the solids, if any, present in the vessel.A more preferred amount of water is at least about 1% wt/wt, and mostpreferably about 1-5% water by wt/wt. While not all possiblecombinations of water and amide-based solvent systems have been tested,it is known that the reaction will proceed with 20% water (wt/wt). Henceit is believed that even higher percentages of water can be used.Optimization of the organic solvent-to-water ratios can be achieved bythe skilled practioner. The use of any amount of water in combinationwith an amide-based solvent is considered to be within the scope of thisinvention.

[0052] The reaction can be run at any temperature above about 60° C.Since there are numerous combinations of amide-based solvent and waterthat can be used, it is not practical to set an exact upper limit to thetemperature since that will vary based on solvent selection and theratio of the selected solvents. The Group I(a) or II(a) metal halideopens the epoxide to give an acyl nitrile. It is hydrolyzed to the acidin the presence of water. But rather than isolate the free acid, aninsoluble salt of the carboxylate is formed by adding about 2 or moreequivalents of a strong base to the reaction vessel. This base forms twosalts, a salt of the cyclohexanoic acid and a salt of HCN which isreleased in the hydrolysis of the acyl nitrile group. The metal cyanideit turns out is soluble in the solvent and the salt of the alkanoic acidprecipitates out of solution. This makes it possible to separate thealkanoic acid salt from the cyanide salt by simply removing the solvent.The invention can be practiced using less than 2 equivalents of base,but that would possibly result in loss of the alkanoic acid because itwould not precipitate out of solution, undesirable from an economicstandpoint. And unreacted HCN could contaminate the alkanoic acid thatdid precipitate out of solution. Hence the preferred practice is to use2 or more equivalents of the base.

[0053] A strong base for the purposes of this invention is any base thatwill form a salt with the cyanide ion. One can use any base strongenough to form these salts; formation of the cyanide salt is the morecritical of the two criteria for determining if a particular base isuseful in this step. Inorganic hydroxides are preferred. For example onecan use LiOH, NaOH, or KOH. One can also use ammonium salts, for exampletetra-alkylammonium hydroxides or NH₄OH. Lithium hydroxide is preferredbecause the lithium cyanide salt is highly soluble in the aqueousaprotic dipolar amide-based solvent, and thus effects more efficient andmore complete removal of the cyanide ion from the acid salt when theamide-based solvent is removed. Lithium cyanide is more soluble in DMFthan is sodium cyanide or potassium cyanide. So it is more advantageousto make lithium the cation in the strong base in the salt-forming stepof the process.

[0054] A perferred practice of this invention is one in which thesolvent(s) are charged to the reaction vessel, lithium bromide is added,and then the epoxide. Once the reaction has gone to completionessentially, two or more equivalents of an aqueous solution of lithiumhydroxide are added, the cyclohexanoic acid salt is precipitated out ofsolution and filtered out, and the solvent discarded. The lithium saltof the cyclohexanoic acid can be further purified if needs be to removeresidual contaminants such as cyanide salts, or converted to the acid bydissolving or suspending the salt in a solvent and acidifying thatmaterial to obtain the free acid.

[0055] A representative schematic of the process is set out in Scheme Iand Scheme II. These graphical representations use specific examples toillustrate the general methodology used in this invention.

[0056] Scheme II illustrates a second very similar set of conditionsthat can be used in this invention. This scheme follows the same routeas the one outlined in Scheme I; some of the conditions in certain stepsare changed.

[0057] The chemistries illustrated in Scheme I are set out in aco-pending U.S. application which has been assigned U.S. Ser. No.60/061,613 (filed Feb. 12, 1997) and also filed as PCT applicationserial number PCT/US98/02749 designating inter alia the U.S.; it hasbeen published as WO98/34584. That application is incorporated herein byreference, particularly as regards the chemistries underpinning steps1-7.

[0058] The chemistries in Scheme II are set out in PCT applicationnumber PCT/EP98/05504 filed Aug. 26, 1998 which, inter alia, designatesthe U.S. as a selected State. The full disclosure of that application isincorporated herein by reference. In addition the details of this secondset of chemistries are given below.

[0059] A general description of the chemistries in Schemes I and IIfollows:

[0060] A mixture of cyclopentyl chloride, isovanillin and potassiumcarbonate in dimethylformarnide is stirred at about 125° C. untilformation of the cyclopentyloxy product is deemed to be complete(approximately 2 hours). The mixture is cooled to 20-25° C., the solid(potassium chloride and potassium bicarbonate) is removed bycentrifugation and is washed with methanol before being discarded. Thedimethylformamide liquors and methanol wash are combined for use in thenext step.

[0061] The solution of the cyclopentyloxy compound in dimethylformamideand methanol is cooled to about 0° C. and treated with sodiumborohydride (approximately 1.5 hours). The temperature is maintainedbelow 5° C. After that the mixture is stirred at 0 to 10° C. for 30minutes and at 25-30° C. until the reduction reaction is deemed to becomplete (approximately 1 hour). Acetic acid 50% is added to destroy theexcess borohydride and the dimethylformarnmide and methanol are removedby distillation in vacuo. After cooling to 20-25° C. the mixture ispartitioned between water and toluene. The toluene phase, containing thealcohol is washed with demineralised water, passed through a filter foruse in the next step.

[0062] The solution of alcohol in toluene is treated with concentratedhydrochloric acid (min 36%) at 15 to 25° C. The organic phase,containing the chloro compound is separated and treated with sodiumbicarbonate to neutralize the HCl traces. The solid (sodium chloride,sodium bicarbonate) is removed by filtration.

[0063] The solution of the chloro compound is concentrated bydistillation in vacuo. After cooling to about 20° C., demineralisedwater, tetrabutylammonium bromide and sodium cyanide are added. Afterthat the mixture is heated to 80° C. and stirred at this temperatureuntil the cyanidation reaction is deemed to be complete (approximately 2hours).

[0064] After cooling to <60° C. the mixture is partitioned between waterand toluene. The toluene phase, containing the cyano compound is washedat 30 to 25° C. with demineralised water, distilled in vacuo to minimumvolume and to this is added acetonitrile. The product solution inacetonitrile is used directly in the next step.

[0065] Solutions of methyl acrylate in acetonitrile and Triton B andacetonitrile are prepared. About 16.6% of the methyl acrylate solutionis added to the cyano compound solution at <25° C. About 12.5% of theTriton B solution is the added, the mixture is stirred for some minutesand then cooled back to <25° C. This addition sequence is repeated threemore times, then the final 33% of the methyl acrylate solution and thefinal 50% of the Triton B solution are added in two portions. Thereaction mixture is stirred at 20 to 25° C. until the reaction is deemedto be complete (approximately 2-3 hours). The acetonitrile is removed byvacuum distillation to minimum volume. The mixture is partitionedbetween cyclohexane/toluene and water at 50° C. The cyclohexane/toluenephases, containing the pimelate is aged for about 1 hour at about 0° C.

[0066] The product is isolated by centrifugation and washed with cold(<0° C.) cyclohexane/toluene. The wet cake vacuum dried at max 50° C. togive the pimelate as an off white to beige powder.

[0067] A 29% methanolic solution of sodium methoxide is added in one lotto a solution of the pimelate in dioxane. The mixture is heated to about75° C. (reflux) and maintained at this temperature until formation ofthe 2-carbomethoxycyclohexan-1-one is deemed complete (approximately 1hour). Much of the methanol is distilled out and replaced with dioxane.Sodium bicarbonate and deminieralised water are added to the. themixture is heated to reflux (about 85 to 88° C.) and maintained at thistemperature until formation of the cyclohexan-1-one is deemed to becomplete (approximately 10 hours).

[0068] After that the mixture is cooled to <60° C. and concentratedhydrochloric acid solution is added to reduce the pH from >10 to 7.5

[0069] Much of the dioxane and methanol is removed by distillation invacuo. After that the mixture is partitioned between cyclohexane/tolueneand water at about 70° C. The organic phase, containing the ketone iswashed twice with demineralised water at about 70° C.

[0070] The product solution is cooled to 10° C. and aged for about 1hour at 9 to 11° C. The product is isolated by filtration and washedwith cold (10° C.) cyclohexane/toluene. the wet cake is vacuum dried atmax 50° C. to give the ketone as an off white powder.

[0071] The dicarbonitrile is prepared from the ketone by treating theketone with chloroacetonitrile in the presence of an inorganic base anda catalytic amount of benzyltriethylammonium chloride (BTEAC). Theketone and a slight excess of chloroacetonitrile in a suitable solventsuch as THF is charged into a mixture of strong base (aqueous potassiumhydroxide) and BTEAC and a water miscible solvent such astetrahydrofuran at reduced temperature, about 0° C. or thereabouts. Thereaction is maintained at about that temperature for the duration of thereaction, usually about 1 hour. The product can be isolated or used as acrude oil.

[0072] The dicarbonitrile is converted to the cyclohexanecarboxylic acidusing a Group I(a) or II(a) metal halide. This reaction is carried outby charging a vessel with solvents; in this instance exemplified by DMF,acetonitrile and water, and the Group I(a) or II(a) metal halide(preferably about 1.5 equivalents), LiBr is illustrated; sweeping thevessel with an inert gas; adding the dicarbonitrile A or B, or a mixtureof A and B; and heating the vessel and its contents to about 100° C. fora number of hours, 8 hours being an example. The reaction is dilutedwith DMF and optionally water. LiOH dissolved in water is added (about a50% molar excess is preferred). A suspension is formed. This is stirredat a slightly elevated temperature (40 to 80° C.) for about an hour orso. The lithium salt is recovered by conventional means.

[0073] The acid is prepared, for example, by suspending the lithium saltin an organic solvent of the likes of ethyl acetate, and treating thesuspension with aqueous mineral acid. The organic solvent is thenrecovered, washed, and concentrated. The product is isolated byconventional means.

[0074] The following examples are provided to illustrate specificembodiments of the invention, not to limit it. What is reserved to theinventors is set forth in the claims appended hereto.

SPECIFIC EXAMPLES Example 1 Preparation of3-cyclopentyloxy-4-methoxybenzaldehyde

[0075] A mixture of cyclopentyl chloride (8.48 g, 0.08 moles),isovanillin (6.12 g, 0.04 moles) and potassium carbonate (1.1 g, 0.08moles) in dimethylformamide (4.04 g) was stirred in the reactor (100 mL)at 120 to 125° C. for 1.5 hours. A sample was taken to verify the batchconversion. Result (GC): 0.5 area % isovanillin (target: <1.0 area %).The mixture was cooled to 20° C. and filtered to remove the solid(potassium bicarbonate, potassium chloride). The wet cake was washedwith methanol.

Example 2 Preparation of 3-cyclopentyloxy-4-methoxybenzyl Alcohol

[0076] The dimethylformamide liquors and methanol wash from Example 1were combined and retransferred into the cleaned reactor. An additionalamount of methanol (8.52 g) was added and the batch was cooled to 0° C.Sodium borohydride (0.49 g, 0.0129 moles) was added in small portionsover 1 hour and 10 minutes maintaining the temperature between 4 and 9°C. The batch was stirred at 7.2 to 10° C. for 30 minutes and then heatedto 25° C. A sample was taken after 110 minutes stirring at 25 to 31° C.and analysed (GC) and the reaction was deemed to be complete. Aceticacid 50% (1.80 g) was charged to the reactor to quench any remainingsodium borohydride. The batch temperature of 24 to 25° C. was maintainedduring this charge. The dimethylformamide and methanol were removed bydistillation in vacuo (end of distillation: 58° C., 6 mbar). Aftercooling to 20-25° C. the mixture was partitioned between water (3.13 g)and toluene (28.07 g). The toluene phase (containing the captionedcompound) was washed with demineralised water (2.65 g).

Example 3 Preparation of4-Chloromethyl-2-cyclopentyloxy-1-methoxybenzene

[0077] The toluene solution from Example 2 was cooled to 20° C. andconcentrated hydrochloric acid (37.5%; 9.80 g) was added keeping thetemperature between 20 and 22.7° C. A sample was taken 40 minutes afterthe addition was complete and analysed (GC) and the reaction was deemedto be complete. The phases were allowed to separate and the lower,aqueous phase discarded. Sodium bicarbonate (1.20 g) was charged to thereactor to neutralize the remaining hydrochloric acid. After stirringfor 15 minutes the mixture was cooled to 23° C. and filtered to removethe solid (sodium bicarbonate, sodium chloride). A part of the toluene(17.07 g) was removed by distillation in vacuo (end of distillation: 28°C., 7 mbar).

Example 4 Preparation of 4-Cyanomethyl-2-cyclopentyloxy-1-methoxybenzene

[0078] After cooling the solution from Example 3 to <25° C.tetra-butylammonium bromide (0.205 g, 0.63 mmoles), demineralised water(2.775 g) and sodium cyanide (1.976 g, 0.039 moles) were added, themixture was heated to 80° C. and then stirred at 78.1 to 80.4° C. for 1hour and 50 minutes. A sample was taken to verify the batch conversion.

[0079] Toluene (5.841 g) and demineralised water (8.76 g) were added,the phases were allowed to separate (at about 54° C.) and the lower,aqueous phase discarded. The toluene phase (containing the product) waswashed with demineralised water (13.32 g). The toluene was removed bydistillation in vacuo (end of distillation: 55° C., 1 mbar).

Example 5 Preparation ofDimethyl-4-cyano-4-(3-cyclopentyloxy-4-methoxy-phenyl)pimelate

[0080] The cyanomethyl compound prepared in Example 4 (9.05 g at 85.4%;7.73 g at 100%; 0.0334 moles) was charged in the reactor (0.5 L) at roomtemperature. Acetonitrile (28.56 g) and demineralised water (0.07 g) wascharged to the reactor. Solutions of methyl acrylate (6.88 g, 0.029moles) in acetonitrile (4.02 g) and methanolic Triton B (40.2% 0.94 g,2.269 mmoles Triton B) in acetonitrile (4.06 g) were prepared. A firstportion, about 16.6% of the methyl acrylate solution (1.81 g) was addedat 20° C. A first portion, about 12.5% of the Triton B solution (0.63kg) was then added. The batch temperature after the addition was 31° C.A second portion, about 16.6% of the methyl acrylate solution (1.82 g)was added at 28° C. A second portion, about 12.5% of the Triton Bsolution (0.63 g) was then added. The batch temperature after theaddition was 36° C. A third portion, about 16.6% of the methyl acrylatesolution (1.81 g) was added at 35° C. A third portion, about 12.5% ofthe Triton B solution (0.62 g) was then added. The batch temperatureafter the addition was 32° C. A fourth portion, about 16.6% of themethyl acrylate solution (1.81 g) was added at 32° C. A fourth portion,about 12.5% of the Triton B solution (0.63 g) was then added. The batchtemperature after the addition was 36° C. A fifth portion, about 33.2%of the methyl acrylate solution (3.64 g) was added at 34° C. A fifthportion, about 25% of the Triton B solution (1.25 g) was then added. Thebatch temperature after the addition was 38° C. The last portion, about25% of the Triton B solution (1.25 g) was then added. The batchtemperature after the addition was 36° C. The reaction mixture wasstirred for 1.5 hours at 20-25° C. The acetonitrile was removed bydistillation in vacuo (end of distillation: 59° C., 20 mbar). Themixture was partitioned at about 50° C. between cyclohexane/toluene(1145.9/254.6 g) and water (559.8 g). The cyclohexane/toluene phase(containing the product was washed with demineralised water (559.8 g) at50 to 52° C. To crystallize the captioned product, the batch was cooledover 50 minutes to 0° C. The batch was then seeded with pimelate andaged for 1 hour at −1 to 1° C. The pimelate was filtered and washed withcyclohexane/toluene (6.51 g/l 0.44 g) and recovered by conventionalmeans.

Example 6 Preparation of4-Cyano-4-(3-cyclopentyloxy-4-methoxyphenyl)cyclohexan-1-one

[0081] The pimelate made in Example 5 (76.52g, 1,8112 moles) was chargedinto the reactor (100 mL). Dioxane (2214 g) and a 29.1% methanolic ofsodium methoxide (0.44 g, 24 mmoles) were added. The mixture was heatedto reflux (77° C.) and stirred at this temperature for 1 hour. A samplewas taken to verify the batch conversion. The methanol was removed bydistillation (16.82 g distillate) to a bottom temperature of 97° C. theloss of dioxane during this distillation was compensated by adding offresh dioxane (121.6 g). Sodium bicarbonate (22.2 g, 26. mmoles) anddemineralised water (2.47 g) were added. The mixture was heated toreflux (87° C.) and stirred at about to 87° C. for 10 hours. A samplewas taken to verify the batch conversion. The content of the reactor wascooled to 78° C. Dioxane (0.13 g) and demineralised water (0.12 g) wereadded to simulate a flush. After cooling to <60° C. concentratedhydrochloric acid (37%, 0.265 g) was added to adjust the pH to 7.5. Thedioxane, methanol and a part of water (27.73 g distilled) were removedby vacuum distillation (end of distillation: 66° C., 305 mbar).

[0082] Under stirring, cyclohexane (180.0 g) and toluene (65.5 g) werecharged to the reactor. The mixture was heated to 70° C. and the phaseswere allowed to separate at 70° C. and the lower, aqueous phase wasdiscarded. The organic phase, containing the captioned ketone was washedin two portions with demineralised water (169.4 g total) at about 70° C.Cyclohexane (165.0 g) was added to the reactor to simulate a flush. Tocrystallize the product, the batch was cooled to 10° C. over 1 hour.Then it was aged for 6 hours at 9 to 11° C. to complete thecrystallization. The product batch was filtered and washed withcyclohexane/toluene (81.5 g/27.2 g).

Example 7 Preparation ofcis-6-[3-(cyclopentyloxy)-4-methoxyphenyl)]-1-oxaspiro[2.5]octane-2,6-dicarbonitrile

[0083] A 500 mL round bottom flask equipped with an overhead stirrer,internal thermometer, and a nitrogen inlet was flushed with nitrogen.The flask was charged with 50% potassium hydroxide in water (22.0 g) andtetrahydrofuran (55.0 mL). While stirring at room temperature,benzyltriethylammonium chloride (0.81 g, 35 mmol, 0.05 equivalent) wasadded. The solution was cooled to 0° C. To a pressure-equalizingaddition funnel was charged a solution containing tetrahydrofuran (55.0mL), 4-cyano-4-(3-cyclopentyloxy-4-methoxyphenyl) cyclohexan-1-one (23.0g, 73 mmol, 1.0 equivalent), and chloroacetonitrile (5.9 g, 78 mmol,1.07 equivalent) at room temperature. While stirring the flasks contentsat 0° C., the solution in the pressure addition funnel was added over 15minutes. The temperature was maintained between 0 and 5° C., and stirredfor one hour. The reaction was warmed to 25° C., diluted with water(90.0 mL), and ethyl acetate (90.0 mL). The solution was stirred andallowed to settle for 30 minutes. The layers were separated, the organiclayer was isolated, and concentrated by vacuum distillation to aresidue. Methylcyclohexane/THF (5:1) (54.0 mL) was added and thesolution was heated to 60° C. then cooled to 20° C. over 90 minutes; theproduct began to crystallize at about 40° C. The suspension was thencooled to 0° C. and held at −0 to 5° C. for two hours. The product wasfiltered and washed with a methanol mixture (46.0 mL) at 0° C. Theproduct was dried to afford the captioned product as a white crystallinesolid.

Example 8 Preparation ofcis-Lithium-4-cyano-4-(3-cyclopentyloxy-4-methoxyphenyl)-r-1-cyclohexanecarboxylate2

[0084]

[0085] To a 1.0 L, 3-neck round bottom flask equipped with an overheadstirrer, internal thermometer and a reflux condenser connect to acaustic scrubber was charged dimethylformamide (200 mL), acetonitrile(200 mL), lithium bromide (32.4 g, 0.37 mol) and water (5.6 g, 0.31mol). The suspension was stirred until a solution was evident, followedby the addition ofcis-6-[3-(cyclopentyloxy)-4-methoxyphenyl)]-1-oxaspiro[2.5]octane-2,6-dicarbonitrile.1,(90.0 g, 0.25 mol). The contents of the flask were heated between 90 and95° C. for 8 to 12 hours. The reaction was cooled to 60° C. and dilutedwith dimethylformamide (270 mL). To the amber solution (60° C.) wasquickly added an aqueous solution of lithium hydroxide (21.65 g, 0.51mol of lithium hydroxide monohydrate dissolved in 112.5 mL of water).The suspension was stirred at 60° C. for 1 hour, cooled to 5° C., andheld at 5° C. for 1 hour. The suspension was filtered, washed with ethylacetate (100 mL) and air dried to provide 2 in 79.5% corr yield.

Example 9 Preparation ofcis-4-cyano-4-(3-cyclopentyloxy-4-methoxyphenyl)-r-1-cyclohexanecarboxylate,3

[0086]

[0087] To a 1.0 L, 3-neck round bottom flask equipped with an overheadstirrer and an internal thermometer was addedcis-lithium-4-cyano-4-(3-cyclopentyloxy-4-methoxyphenyl)-r-1-cyclohexanecarboxylate,2 (58.5 g, 0.167 mol) and ethyl acetate (500 mL). The light suspensionwas stirred at ambient temperature followed by the addition of 3Naqueous HCl (70 mL, 0.21 mol). The reaction was stirred for ten minutesand transferred to a separatory funnel. The organic layer was isolatedand washed once with water (100 mL). The organic layer was isolated andfiltered into a clean 1.0 L, 3-neck round bottom flask equipped with adistillation head and an overhead stirrer. The reaction was concentratedby distilling off ethyl acetate (200 mL). The contents of the flask werecooled to 60° C. followed by the addition of heptane (275 mL). Thesuspension was cooled to 5° C., held at 5° C. for 2 hours, filtered, andwashed with cold (5° C.) heptane (50 mL). The product was dried in avacuum oven to constant weight to afford 50.0 g (85%) of 3.

What is claimed is:
 1. A method for making a compound of formula I

R₁ is —(CR₄R₅)_(n)C(O)O(CR₄R₅)mR₆, —(CR₄R₅)_(n)C(O)NR₄(CR₄R₅)_(m)R₆,—(CR₄R₅)_(n)O(CR₄R₅)_(m)R₆, or —(CR₄R₅)_(r)R₆ wherein the alkyl moietiesmay be optionally substituted with one or more halogens; m is 0 to 2; nis 1 to 4; r is 0 to 6; R₄ and R₅ are independently selected fromhydrogen or a C₁₋₂ alkyl; R₆ is hydrogen, methyl, hydroxyl, aryl, halosubstituted aryl, aryloxyC₁₋₃ alkyl, halo substituted aryloxyC₁₋₃ alkyl,indanyl, indenyl, C₇₋₁ polycycloalkyl, tetrahydrofuranyl, furanyl,tetrahydropyranyl, pyranyl, tetrahydrothienyl, thienyl,tetrahydrothiopyranyl, thiopyranyl, C₃₋₆ cycloalkyl, or a C₄₋₆cycloalkyl containing one or two unsaturated bonds, wherein thecycloalkyl and heterocyclic moieties may be optionally substituted by 1to 3 methyl groups or one ethyl group; provided that: a) when R₆ ishydroxyl, then m is 2; or b) when R₆ is hydroxyl, then r is 2 to 6; orc) when R₆ is 2-tetrahydropyranyl, 2-tetrahydrothiopyranyl,2-tetrahydrofuranyl, or 2-tetrahydrothienyl, then m is 1 or 2; or d)when R₆ is 2-tetrahydropyranyl, 2-tetrahydrothiopyranyl,2-tetrahydrofuranyl, or 2-tetrahydrothienyl, then r is 1 to 6; e) when nis 1 and m is 0, then R₆ is other than H in —(CR₄R₅)_(n)O(CR₄R₅)_(m)R₆;X is YR₂, halogen, nitro, NH₂, or formyl amine; X₂ is O or NR₈; Y is Oor S(O)_(m′), m′ is 0, 1, or 2; R₂ is independently selected from —CH₃or —CH₂CH₃ optionally substituted by 1 or more halogens; R₃ is hydrogen,halogen, C₁₋₄ alkyl, CH₂NHC(O)C(O)NH₂, halo-substituted C₁₋₄ alkyl,—CH═CR_(8′)R_(8′), cyclopropyl optionally substituted by R_(8′), CN,OR₈, CH₂OR₈, NR₈R₁₀, CH₂NR₈R₁₀, C(Z′)H, C(O)OR₈, C(O)NR₈R₁₀, orC≡CR_(8′) R₈ is hydrogen or C₁₋₄ alkyl optionally substituted by one tothree fluorines; R_(8′) is R₈ or fluorine; R₁₀ is OR₈ or R₁₁; R₁₁ ishydrogen, or C₁₋₄ alkyl optionally substituted by one to threefluorines; Z′ is O, NR₉, NOR₈, NCN, C(—CN)₂, CR₈CN, CR₈NO₂, CR₈C(O)OR₈,CR₈C(O)NR₈R₈, C(—CN)NO₂, C(—CN)C(O)OR₉, or C(—CN)C(O)NR₈R₈; R′ and R″are independently hydrogen or —C(O)OX where X is hydrogen or metal orammonium cation; which method comprises: a) combining a Group I(a) orGroup II(a) metal halide, with an aprotic dipolar amide-based solventand water and a compound of formula II(a) or II(b),

 where R₁, R₃, X₂ and X are the same as for formula (I) b) heating thecombination to a temperature of at least about 60° for several hours,optionally under an inert atmosphere; c) precipitating out a compound offormula (I) by adding a strong base to said combination; d) removing theamide-based solvent and water from said precipitate, and optionally 1)purifying further the precipitate, or 2) acidifying the precipitate toobtain the free acid.
 2. The process of claim 1 wherein the product is acompound wherein R₁ is —CH₂-cyclopropyl, cyclopentyl,3-hydroxycyclopentyl, methyl or CF₂H; X is YR₂; Y is oxygen; X₂ isoxygen; and R₂ is CF₂H or methyl; and R₃ is CN.
 3. The process of claim1 or 2 wherein the Group I(a) or II(a) metal halide is lithium ormagnesium halide.
 4. The process of any one of claims 1-3 wherein theGroup I(a) or II(a) metal halide is lithium bromide or magnesiumbromide.
 5. The process of any one of claims 1-4 in which the aproticdipolar amide-based solvent is dimethylformamide, dimethylacetamide, orN-methyl pyrrolidinone.
 6. The process of any one of claims 1-5 whereinthe Group I(a) or II(a) metal halide is lithium bromide and theamide-based solvent is dimethylformamide.
 7. The process of any one ofclaim 1-6 wherein water is present in an amount greater than 0.1% byweight/weight of the contents of the reaction vessel.
 8. The process ofany one of claims 1-7 in which the strong base is lithium hydroxide. 9.The process of any one of claim 1-8 wherein the compound of formulaII(a) or II(b) iscis-6-[3-(cyclopentyloxy)-4-methoxyphenyl)]-1-oxaspiro[2.5]octane-2,6-dicarbonitrile.10. A product of the process of any one of claims 1-9 which iscis-lithium-4-cyano-4-(3-cyclopentyloxy-4-methoxyphenyl)-r-1-cyclohexanecarboxylate.11. A compound which iscis-lithium-4-cyano-4-(3-cyclopentyloxy-4-methoxyphenyl)-r-1-cyclohexanecarboxylate.12. A compositon of matter comprising essentially purecis-lithium-4-cyano-4-(3-cyclopentyloxy-4-methoxyphenyl)-r-1-cyclohexanecarboxylate.